Rapid manufacturing of porous metal prostheses

Abstract

An orthopaedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopaedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopaedic prosthesis.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims priority from U.S. Provisional Patent Application Ser. No. 61 / 507,151, filed Jul. 13, 2011, the disclosure of which is hereby expressly incorporated by reference herein in its entirety.FIELD OF THE DISCLOSURE[0002]The present disclosure relates to porous metal prostheses. More particularly, the present disclosure relates to rapid manufacturing of porous metal prostheses.BACKGROUND OF THE DISCLOSURE[0003]Orthopaedic prostheses are commonly used to replace at least a portion of a patient's bone following traumatic injury or deterioration due to aging, illness, or disease, for example.[0004]When the orthopaedic prosthesis is implanted into a joint, the orthopaedic prosthesis may be configured to articulate with an adjacent orthopaedic component. For example, when the orthopaedic prosthesis is implanted into the patient's hip joint, the orthopaedic prosthesis may be socket-shaped to receive and articulate with an adjace...

AI Technical Summary

Benefits of technology

[0006]The present disclosure provides an orthopaedic prosthesis having a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. The present disclosure also provides a method for rapidly manufacturing the orthopaedic prosthesis, such as by performing a laser sintering process.

[0007]According to an embodiment of the present disclosure, a method is provided for rapidly manufacturing an orthopaedic prosthesis. The orthopaedic prosthesis has a porous substrate, the porous substrate including an outer surface and a plurality of ligaments that define pores beneath the outer surface. The method includes the steps of: depositing a plurality of metal powder particles onto the outer surface of the porous substrate; allowing at least a first portion of the plurality of metal powder particles to enter the pores beneath the outer surface of the porous substrate, the first portion of the plurality of metal powder particles being sized to fit within the pores of the porous substrate; and applying an energy source to the first portion of the plurality of metal powder particles to form solid metal, the solid metal interdigitating into the pores of the porous substrate.

[0008]According to another embodiment of the present disclosure, a method is provided for rapidly manufacturing an orthopaedic prosthesis. The orthopaedic prosthesis has a solid metal component and a porous metal component, the porous metal component including a plurality of ligaments that define pores. The method includes the steps of: depositing a plurality of metal powder particles into the pores of the porous metal component; and directing an energy source into the pores of the porous metal component to convert the plurality of metal powder particles in the pores to solid metal in the pores, the solid metal in the pores coupling the solid metal component to the porous metal component.

Problems solved by technology

Diffusion bonding, however, requires a significant amount of time to complete and subjects the orthopaedic prosthesis to high temperatures.

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